Epic fail drilling into aluminum

[alwaysFlOoReD]

When I'm cutting or drilling aluminum, I use wd40 as cutting fluid. It stops the bit or blade from clogging up.

 

[fastpakr]

When I'm cutting or drilling aluminum, I use wd40 as cutting fluid. It stops the bit or blade from clogging up.

@Curious Hound mentioned that as well. I did try it this evening, but I think I was just spinning the grinder too fast and it overheated the metal. Next time I’ll have the line pressure much further down.

 

[JoshT]

Just tuning in. Pretty crazy that you're having that much trouble drilling Chinese aluminum. I work/worked on military aircraft. We're talking better aluminum that you'll ever get off Amazon, and some Titanium too. Never seen the sheetmetal guys at work have that much trouble drilling out a hole for a fastener.

 

[fastpakr]

Just tuning in. Pretty crazy that you're having that much trouble drilling Chinese aluminum. I work/worked on military aircraft. We're talking better aluminum that you'll ever get off Amazon, and some Titanium too. Never seen the sheetmetal guys at work have that much trouble drilling out a hole for a fastener.

It’s comically bad. I wish there was an easy way to let you guys try your hand at it and we could figure it out.

The other day I reached out to a local friend that seemed likely to have answers. He asked me to bring it by his house and when I arrived he suggested I should surrender my man card over this. Then he joined me in abject failure.

 

[Curious Hound]

he suggested I should surrender my man card over this. Then he joined me in abject failure.

 

[alwaysFlOoReD]

I'm still thinking bits that are wrong cutting geometry. I've seen enough that I've had to sharpen before they work properly.
Or dull from the start.

 

[JoshT]

It’s comically bad. I wish there was an easy way to let you guys try your hand at it and we could figure it out.

The other day I reached out to a local friend that seemed likely to have answers. He asked me to bring it by his house and when I arrived he suggested I should surrender my man card over this. Then he joined me in abject failure.

Did he surrender his?

 

[Roert42]

try double cut carbide burrs instead of single cut. Clogs less in soft metal.

 

[fastpakr]

I'm still thinking bits that are wrong cutting geometry. I've seen enough that I've had to sharpen before they work properly.
Or dull from the start.

That seems like a completely reasonable explanation.

 

[pjtoledo]

are you putting a solid backing behind the spot? to at least get the hole started.
if the part bends when pushed it's negating the angle of the drill tip.

what happens if you sand some of the coating off, it may be acting as a lube and laughing at the drill.

I can relate to drilling difficulties, recently had a new 1/8 HSS bit totally refuse to cut mild steel.
switched to a 135 degree bit and went right thru the mushed dimple.

 

[pjtoledo]

View attachment 145985View attachment 145986

Left bit is the one I tried to drill with last night for several minutes. Brand new prior, and the one on the right is brand new for comparison.

Second picture shows where I tried using my die grinder. It definitely chewed away some material but I’ll need to be more intentional about preparing to avoid scratches when it slips. Before and after doing that, I tried one of the new cobalt bits that came in the mail today. Still nothing… just blissfully spinning over the surface of the metal.

are you sure that's aluminum?

 

[fastpakr]

are you sure that's aluminum?

I’m not sure what year it is at this point.

 

[fastpakr]

are you putting a solid backing behind the spot? to at least get the hole started.
if the part bends when pushed it's negating the angle of the drill tip.

what happens if you sand some of the coating off, it may be acting as a lube and laughing at the drill.

I can relate to drilling difficulties, recently had a new 1/8 HSS bit totally refuse to cut mild steel.
switched to a 135 degree bit and went right thru the mushed dimple.

I didn’t have the back of the material supported. Maybe I can support the side boxes on the corner of a saw horse when I get to them. Short of cutting a 2x4 to fit and wedging it in there, it’s a little tough to directly support it. Maybe I can find a tension rod to put in the middle.

There’s definitely some kind of coating on the material, because you can see it start to burn back from the hole when using the die grinder and letting it get too hot. That said, drilling didn’t really go any better after it was burned away…

 

[fastpakr]

Should I try something like these?

https://a.co/d/04JazmxS

 

[alwaysFlOoReD]

Should I try something like these?

https://a.co/d/04JazmxS

I didn't know they made a solid carbide bit. Pretty pricey! So yes, try them and report back.